Break-away multi-purpose flooring transition

ABSTRACT

The invention is a joint cover assembly for covering a gap adjacent an edge of a panel that covers a sub-surface, and a method of covering such a gap. The assembly can be manipulated to form an end molding, a T-molding, a hard surface reducer, a carpet reducer, and/or a stair nose molding. A kit can include the joint cover assembly an a tool for forming a flooring transition from a generic element having break-away sections.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Appl. No.60/808,121, having been filed May 25, 2006, incorporated by reference inits entirety.

BACKGROUND

1. Field of the Invention

The invention is an integral multi-purpose structure which can beseparated into various flooring transitions such as T-moldings, hardsurface reducers and end moldings.

2. Background of the Invention

Hard surface floors, such as wood or laminate flooring, have becomeincreasingly popular. As such, many different types of this flooringhave been developed. Generally, this type of flooring is assembled byproviding a plurality of similar panels. The differing types of panelsthat have developed, of course, may have differing widths andthicknesses. The same is true when a laminate floor (often referred toas a “floating floor”) abuts another hard surface, such as a resilientsurface (such as vinyl), tile or another laminate surface, a ceramicsurface, or other surface, e.g., natural or engineered wood flooring.Thus, when laminate panels having different thicknesses or differentfloor covering materials are placed adjacent to a similar or dissimilar,transition moldings are often used to create a transition between thesame.

Additionally, one may desire to install floor panels adjacent to an areawith different types of material. For example, one may desire to haveone type of flooring in a kitchen (e.g., resilient flooring, laminateflooring or ceramic tile), and a different appearance in an adjacentdining room (e.g., solid wood or carpeting), and an entirely differentlook in an adjacent bath. Therefore, it has become necessary to developa type of molding or floorstrip that could be used as a transition fromone type of flooring to another, either between rooms, or differentportions of the same room.

A problem is encountered, however, when flooring materials that aredissimilar in shape or texture are used. For example, when a hard flooris placed adjacent a carpet, problems are encountered with conventionaledge moldings placed therebetween. Such problems include difficulty incovering the gap that may be formed between the floorings havingdifferent height, thickness or texture.

Moreover, for purposes of reducing cost, it is desirable to be able tohave a molding that is versatile, having the ability to cover gapsbetween relatively coplanar surfaces, as well as surfaces of differingthicknesses.

It would also be of benefit to reduce the number of molding profilesthat need to be kept in inventory by a seller or installer of laminateflooring. Thus, the invention also provides a method by which the numberof moldings can be reduced while still providing all the functionsnecessary of different styles of transition moldings.

SUMMARY OF THE INVENTION

The invention is a joint cover assembly for covering a gap between edgesof adjacent floor elements, such as floor panels of laminate or wood,although it may also be used as a transition between a laminate paneland another type of flooring, e.g., carpet, vinyl, ceramic, and wood.The assembly typically includes a body having a foot positioned along alongitudinal axis, and a first arm or member extending generallyperpendicularly from the foot. The assembly may include a second armalso extending generally perpendicular from the foot.

The outward-facing surface of the assembly may be formed as a single,unitary, monolithic surface that covers both the first and second arms.This outward-facing surface may be decorated, for example, with alaminate or a paper, such as a monochromatic or patterned décor,impregnated with a resin, in order to increase its aesthetic value, tomatch, blend or contrast with the floor panels. Preferably, the outwardfacing surface has incorporated therein at least one material toincrease its abrasion resistance, such as at least one type of hardparticles of silica, alumina, diamond, silicon nitride, aluminum oxide,silicon carbide, cerium oxide and similar hard particles, preferablyhaving a Moh's hardness of at least approximately 6. This outward-facingsurface may also be covered with other types of coverings, such as cork,foils (such as paper or thermoplastic foils), paints, papers (optionallystainable), polyurethane (optionally cured), printable surfaces (whichmay be the surface itself), fiber glass, glass fiber reinforcedplastics, or a variety of other decorative elements, including, but notlimited to, wood veneer, ceramic (such as tiles), metal, vinyl or otherdecorative materials.

The assembly is preferably provided with a securing means, such as aclamp or track, to prevent the assembly from moving out of position onceassembled. In one embodiment, the securing means is a clamp, designed tograb the foot. Preferably, the clamp includes a groove into which thefoot is inserted. In a preferred embodiment, the clamp or track may bejoined directly to a subsurface below the floor element, such as asubfloor, by any conventional means, such as a nail, screw or adhesive.

A shim may also be placed between the foot and the subfloor to providefor height adjustments to allow the assembly to be used in varioussituations. In one embodiment, the shim may be positioned on theunderside of the clamp; however, if a clamp is not used, the shim may bepositioned between the foot and the subfloor. The shim may be adhered toeither the foot or subfloor using an adhesive or a conventionalfastener, e.g., nail or screw.

The assembly is typically formed from one of a variety of materials,such as a core covered with carpet, laminate, ceramic or wood tile,linoleum, turf, metal, paper, natural wood or wood veneer, vinyl,ceramic or composite finish, or any type of surface covering, while thecore is generally formed from wood, engineered wood, fiberboard, such ashigh density fiberboard (HDF) or medium density fiberboard (MDF),flaxboard, plastics, or other structural material, such as metals (e.g.,aluminum, copper, brass, alloys thereof and stainless steel) orcomposites, and at least over a portion of the surface thereof may becovered with a foil (metal, plastic, etc.), cork, a plastic, a paper, adécor or a laminate to match or contrast with the first and second arms,or other materials, such as those discussed by U.S. Pat. Nos. 6,860,074and 6,898,911, each of which is herein incorporated by reference in itsentirety. Preferred plastics include extrudable and/or moldablethermosetting and thermoplastic resins, the latter including highdensity olefins and PVC.

The assembly may additionally be used to cover gaps betweentongue-and-groove type panels, such as glued or glueless laminate floorpanels, or even other types of flooring which are secured to asubsurface.

An adhesive, such as a glue, a microballoon adhesive, contact adhesive,or chemically activated adhesive, including a water-activated adhesive,may be also positioned on any of the pieces of the assembly to eitherhold the assembly together or in place. Of course, such an adhesive isnot necessary, but may enhance or supplement the fit and positioning ofthe assembly over the gap between the floor elements. Additionally, theadhesive may assist in creating a more air-tight or moisture-tightjoint.

The assembly may be used in other non-coplanar areas, such as the edgebetween a wall and a floor, or even between the run and rise of stairs.For example, the assembly may include the first and second arms, andfoot as described above, but instead of transitioning between two floorelements placed in the same plane, may form the joint between thehorizontal and vertical surfaces of a single stair element.

The inventive assembly may be used for positioning between adjacenttongue-and-groove panels; in this regard, the assembly functions as atransition molding, which provides a cover for edges of similar ordissimilar surfaces. For example, when installing floors in a home, theassembly could be used to provide an edge between a hallway and abedroom, between a kitchen and living or bathroom, or any areas wheredistinct flooring is desired. Additionally, the assembly may beincorporated into differing types of flooring, such as wood, tile,linoleum, cork, carpet, or turf.

The invention also is drawn to an inventive method for covering a gapbetween adjacent panels of a generally planar surface. The methodincludes multiple steps, including, inter alia, manipulating a genericelement by removing a part of the generic element to produce one or moremoldings, and thereafter, installing the moldings where needed.

The invention additionally includes a new and innovative securing meansused to install both the inventive moldings as described herein, as wellas other moldings, such as those described by U.S. Pat. Nos. 6,517,935,and 6,898,911, and WO0240809 (each of which is herein incorporated byreference in its entirety). This securing means is, most often, a trackor clamp which can be glued, or otherwise secured to a subfloor and/orone or more flooring elements.

Other objects, features and advantages of the present invention willbecome apparent from the following detailed description. It should beunderstood, however, that the detailed description and the specificexamples, while indicating preferred embodiments of the invention, aregiven by way of illustration only, since various changes andmodifications within the spirit and scope of the invention will becomeapparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side-view of a structure from which the moldings of theinvention can be made.

FIGS. 2, 3 and 4 are side-views of intermediate elements which can beused in the construction of the molding of the invention;

FIG. 5 is a side-view of a completed generic element in accordance withthe invention;

FIG. 6 is a side-view of a T-molding formed from the generic element ofFIG. 5.

FIG. 7 is a side-view of one carpet reducer embodiment formed from thegeneric element of FIG. 5;

FIG. 8 is a side-view of a hard surface reducer formed from the genericelement of FIG. 5.

FIG. 9 depicts two end-moldings in accordance with the invention.

FIG. 10 shows a different carpet reducer/hard surface reducer inaccordance with the invention.

FIG. 11 represents a T-molding installed with the track of theinvention.

FIG. 12 is a view of the track used in FIG. 11.

FIG. 13 represents an installation of the reducer of FIG. 10 using thetrack of FIG. 11.

FIG. 14 shows an installed end molding in accordance with the invention.

FIG. 15 depicts a breakaway combination hard surface reducer/carpetreducer in accordance with the invention.

FIG. 16 shows another T-molding embodiment formed from the combinationof FIG. 15.

FIG. 17 is an end molding formed from the combination of FIG. 15.

FIG. 18 represents a carpet transition formed from the combination ofFIG. 15.

FIG. 19 represents an embodiment similar to the combination of FIG. 15.

FIG. 20 shows a carpet transition formed from the combination of FIG.19.

FIG. 21 shows a T-molding formed from the combination of FIG. 19.

FIG. 22 shows end moldings formed from the combination of FIG. 19.

FIG. 23 represents an additional break away molding of the invention.

FIG. 24 is another T-molding with a break away feature.

FIG. 25 is a reversible CR/HSR.

FIG. 26 shows two end moldings.

FIG. 27 shows a track which can be used with embodiments of theinvention.

FIG. 28 represents an assembled and installed carpet reducer.

FIG. 29 represents an assembled and installed hard surface reducer.

FIG. 30 shows a combination HSR/CR with two break away sections.

FIG. 31 is an end molding with a track after the track has beenseparated.

FIG. 32 shows another T-molding of the invention installed in its track.

FIGS. 33 and 34 depict a stair nose attachment of the invention.

FIGS. 35-37 show elements of the generic molding of the invention,indicating a construction method.

FIGS. 38-41 show additional embodiments of the generic molding of theinvention, and products produced therefrom.

FIG. 42 schematically represents a generic element, having been providedwith cuts by a laser.

FIGS. 43 and 44 schematically show shaped core materials before asurface material is applied and the core material modified to its finalshape.

FIGS. 45A-E schematically show alternative edges of a cutting bladewhich can be used in a tool in accordance with the invention.

FIG. 46 is a perspective view of a cutting tool which can be used inaccordance with the invention.

FIG. 47 is an exploded perspective view of the cutting tool of FIG. 46.

FIG. 48 is a schematic representation of an alternate cutting tool to beused in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a structure 1, from which the present invention can beformed. Structure 1 typically has a core 1A, an upper face 1B, a firstlateral face 1C, a second lateral face 1D and a lower face 1E.

Preferably, core 1A is formed from a fiberboard, such as high-densityfiberboard (HDF) or medium-density fiberboard (MDF), plastic, wood,engineered wood, metal, composites, gypsum, high-density fiberreinforced plaster, or other natural or synthetic material such as cork,or any additional material, such as described in U.S. Pat. No.6,860,074, herein incorporated by reference in its entirety. Preferredplastics include extrudable thermoset and thermoplastic resins, thelatter including high density olefins and polyvinylchloride. Inpreferred embodiments of the invention, the core 1A is unitary, i.e., itis a single piece/unit, not a multi-piece element, held together byglues, adhesives, joints, etc.

The decorative outer face can have a variety of finishes, such asvarnishes, lacquers, paints, polyurethane, hard surfaces (optionallycontaining hard particles, to increase the durability, e.g., abrasionand scratch resistance, of the surface materials), such as laminates(such as taught by U.S. application Ser. No. 10/902,062, hereinincorporated by reference in its entirety), or hardwood flooringfinishes, veneers, foils, stainable papers, or digital printing or otherflooring materials, such as vinyl, metal, composites or plastics ornatural materials such as cork. It is additionally within the scope ofthe invention to provide the decorative outer face of quarter round 6with ceramic or wood tiles, as taught by U.S. Pat. No. 6,860,074.Typical laminates which can be used are those taught by U.S. Pat. No.6,517,935 (herein incorporated by reference in its entirety), includingmonochromatic or patterned (including random) décor sheets which may ormay not be impregnated with a thermosetting resin, and a cellulosicoverlay paper, such as one made from alpha-cellulose, which also may ormay not be impregnated with a resin. Other laminates include ones inwhich the overlay is eliminated, and may be substituted by a polymercontaining cellulosic particles, evenly or randomly distributedthroughout a (typically otherwise clear) resin. The outer surface may bea conventional laminate, such as a high pressure laminate (HPL), directlaminate (DL), compact laminate (CPL) or a post-formable laminate (asdescribed in U.S. application Ser. No. 08/817,391, herein incorporatedby reference in its entirety); a foil; a print, such as a photograph ora digitally generated image; or a liquid coating including, for example,aluminum oxide. Thus, in the event natural wood or wood veneer is notselected as the material, the appearance of wood may be simulated bycoating the decorative outer surface with a laminate having a decor thatsimulates wood. Alternatively, the decor can simulate marble, ceramic,terrazzo, stone, brick, inlays, or even fantasy patterns.

In a preferred embodiment, the decorative face or surface includes alaminate formed from a thermosetting resin, having a décor sheet,optionally an overlay layer (with or without cellulosic fibers atop ortherein) or sheet and hard particles therein in order to impart anabrasion resistance thereto, which is affixed or joined to the remainderof the quarter round 6 in a high-pressure laminate process step. Suchlaminate may be affixed as described by U.S. Pat. No. 6,805,951, hereinincorporated by reference in its entirety. The outer face can be otherfinishing materials such as thermoplastic containing laminates, woodveneers, thermosetting polymers, such as melamine or phenolic resins,thermoplastic polymers such as olefins, foils (such as thermosetting,thermoplastic, paper or metal foils), optionally impregnated with orwithout hard particles, polyesters, vinyls, metals (such as sheets orstrips), or combinations thereof. For example, the outer face caninclude multiple elements, as described herein. It is additionallyconsidered within the scope of the invention to affix a material to theouter face during a direct lamination step, as is known in the art.

Often, the outer face is provided with a patterned paper sheet therein,wherein the pattern resembles a natural or synthetic object, such aswood, ceramic, stone (including marble and granite), or fantasy patterns(i.e., those not found in nature), including a monochromatic or randomfield. The specific décor can be selected to enhance the appearance ofthe surfaces which will be adjacent to quarter round 6 when installed.Such enhancement can be accomplished by matching exactly the visualpattern to that of the adjacent surface, or by contrasting the patterns,for example, such that when installed, a visual pattern extends from aflooring element (wall base or wall), onto and possibly completelyacross, the molding, as described by U.S. Patent Application PublicationNo. 2002/0038924, filed Sep. 28, 2001, herein incorporated by referencein its entirety.

The moldings of the invention typically have a durability rating. Asdefined by the European Producers of Laminate Flooring, such productscan have an abrasion resistance rating of anywhere from AC1 to AC5.Typical abrasion resistances are >300 cycles, >400 cycles, >500 cycles,at least 900 cycles (AC1), at least 1800 cycles (AC2), at least 2500cycles (AC3), at least 4000 cycles (AC4) and at least 6500 cycles (AC5),as measured by European Standard EN 13329 (Annex E). Typical productsaccording to the invention can also have impact resistance ratings ofIC1, IC2 or IC3, as measured by European Standard EN 13329.

Moreover, it is possible to provide a texture which enhances the patternof the underlying paper sheet or printed image. Such texturing can becreated to be “in register” with, offset from, or to contrast with theimage of, e.g., the paper sheet. Such texturing may be created byphysical pressing, e.g., embossing (as taught by U.S. application Ser.No. 10/440,317, U.S. Pat. No. 7,003,364, and WO9731775 and WO9731776,each of which is herein incorporated by reference in its entirety) orchemically created (as taught by U.S. Pat. No. 6,991,830, hereinincorporated by reference in its entirety). The texture can be selectedto enhance (e.g., match or contrast with) any texture of adjacentsurfaces. The texture may also be provided such that features of thetexture extend from a flooring element (or wall base or wall) onto, andpossibly completely across, the molding, which texture may, or may notcoincide with the underlying décor.

Although core 1A is shown as being a single unitary structure withoutany joints or connections therein, it is considered within the scope ofthe invention to form core 1A by joining two or more separate elements.Such separate structures need not be of the same material(s), and may bejoined by, for example, by friction joints, tongue-and-groove joints,compression joints, glue, adhesive strip, double-sided tape, or anycombination thereof. Although FIG. 1 shows core 1A as being solid, it isadditionally considered within the scope of the invention to utilize ahollow structure, optionally with one or more supports or reinforcementsprovided in the interior thereof, or a composite core, incorporating aninterlayer of a softer and/or resilient material, e.g., balsa or otherrelatively soft wood, plastic, rubber, paper, or foamed materials, incombination with a wood-fiber layer. Such an interlayer is optionallypositioned in locations to facilitate removal, such as by peeling, toform the desired shapes of the invention.

In order to achieve the generic molding of the invention, preferably,structure 1 is provided with one or more cuts 2. Such cuts 2 can becreated by milling or cutting with, for example, a blade or even alaser, on or into core 1A of structure 1. Alternatively, however, it ispossible to create structure 1 with cuts 2 already therein, by, forexample, an extrusion or other molding process. The particular locationand number of cuts 2 are selected based upon the final shapes to becreated, as will be described below. Preferably, however, structure 1 isprovided with a first cut 2A in face 1C, a second cut 2B in upper face1B, and a third cut 2C in face 1D, with no cuts in lower face 1E, as isshown in FIG. 2. Lower face 1E may be provided with a groove, whichgroove can be sized and shaped to accommodate for heads of screws usedto affix the securing elements to the subfloor.

Known lasers include gas lasers (e.g., CO₂, CO, HeNe, argon), having apower output of between 5 and 100 W, up to 100 kW, preferably 20-60 W,and more preferably approximately 30 W, having a wavelength in the rangeof 5 μm-550 nm, typically 7-15 μm or 450-550 nm. Other known lasersinclude metal ion lasers (e.g., HeAg and NeCu), having wavelengthsbetween 220 and 250 nm, chemical lasers (e.g., HF and Deuteriumflouride), having wavelengths between 2700 and 4000 nm, excimer, solidstate, semiconductor (e.g., Nd:YAG) and dye lasers. However, theparameters of any laser used to produce a cut should be selecteddepending upon, in part, on issues such as the material to be cut, thedepth and/or length of the cut. The cutting laser can be part of aflying optic machine—where the cutting laser moves over the structure tobe cut, although it is considered within the scope of the invention toprocess the workpiece by moving the workpiece with respect to thecutting laser.

According to a preferred embodiment, laser scoring can penetrate at anydesired depth depending upon the material that is being used anddepending upon the speed and strength of the laser used when scoring thematerial. Laser strength can vary from 5 W to 100 kW, preferably withina range of 4 kW to 8 kW when scoring HDF or MDF material and otherstrengths used depending upon the materials and speed of scoring. As thelaser cuts are substantially narrow, the laser cut or scoring does notneed to be filled with shims or other materials for support (althoughshims are not prohibited).

In one generic element 1110 according to the invention (FIG. 42), thepreferred opening of each laser score or cut 1110 is approximately0.05-1 mm, most preferably approximately 0.3 mm, however it can be lessor greater than this measurement. The opening typically corresponds tothe type and thickness of the blade used to cut the surface materialabove the cut, by example a 0.3 mm opening using a blade slightly lessthan 0.3 mm or even less than 0.3 mm to 0.2 mm or slightly less canproduce a cleaner cut edge with as little unsupported surface material1111, surface material at the edge of the cut that does not have corematerial supporting it, as possible. The ideal opening and type bladeand blade thickness will leave a smooth cut of the surface material withas much supporting core material as possible. When a larger opening isused with a smaller blade thickness, by example, 0.6 mm opening with a0.3 mm blade, a larger portion around the cut edge of the surfacematerial is left unsupported by core material. This configuration isless preferred because unsupported surface material can partially crack,tear and/or separate. In such a configuration, the cut edge can besanded or otherwise smoothed to cure the cracks, tears, etc.

The horizontal laser cuts 1110 can be parallel to the top surface of themolding. Specifically, one or both of an upper cut definition 1010A anda lower cut definition 1010B can be parallel to the surface of themolding. However, either or both of the upper cut definition 1010A andlower cut definition 1010B can be at an angle, i.e., not parallel, tothe surface of the molding (the upper surface and/or the bottom surface,which are preferably, but need not be, parallel). A vertical laser cut1112 can be used as well. FIG. 43 shows an example the generic element1100, having been provided with the parallel cuts 1110, but prior toaffixing of the surface material 1111, while FIG. 44 shows the genericelement 1100 with angled cuts 1110. Such cuts 1110 are typicallyapproximately 0.8 mm at the opening, and taper to be linear at theinnermost portion, and are typically cleaned (e.g., brushing and/orblowing) to remove any remaining char and soot. A leg 1113 of thismolding part which is also the material that is held by a track (notshown), can be penetrated by the vertical laser cut with a correspondingV groove 1114 formed, e.g., by milling, on the underside of the “leg”such that when the surface material 1111 is cut and pressure is appliedto separate the generic element 1110 (to form, e.g., the end molding 22or 402), the material between the laser cut and the milled groove willbreak in a desired location. When milling the underside of the genericelement 1110, a variety of milling techniques can be used. Since the leg1113 is almost divided in half by laser scoring or cutting and milling,additional strength can be given each half by increasing the radius ofthe cuts where the underside surface of the T and the junction where theleg joins the underside of the T. By increasing the radius at this pointadditional strength can be given to each half of the leg 1113. Thus,although shown as being right angles. such angles may also be rounded.

Also this same practice can be accomplished where the HSR and CR partsof the molding are attached to the underside of the “T”, increasing thestrength of these parts as desired as well as the amount of corematerial that remains between the end of the cut or laser score andwhere the underside milling begins on each piece.

The preferred use is for cutting laminate, foil, wood veneer, coveredflooring transitions or wall trim.

Typically, cuts 2 penetrate the respective face 1B-D, but do not make aseparate piece from parts of structure 1. Depending on the material usedfor core 1A as well as the desired force necessary, as will be describedbelow, the depth of cuts 2 can vary greatly. If, however, covering 4A(as described below) is strong enough, it is possible for one or morecuts 2 to separate a part of structure 1, because the covering 4A canmaintain the structural integrity. It is also within the scope of theinvention to form cuts 2 such that a frangible connection is madebetween various sections of structure 1.

In a preferred embodiment, filler material, such as shims 3A-C areinserted into cuts 2A-C, respectively. Shims 3 preferably have a widthslightly smaller than the width of the respective cut 3A-C. As a result,shims 3 typically fit snugly in the cut 3. Although no particular lengthfor shims 3 is required, it is preferable that shims 3 are substantiallyshorter than the length of the respective cut 2, which cut can havediffering dimensions across its length and/or width. Such may beaccomplished by using tools, e.g., blades and lasers, of differentdimensions. Although cuts 2 and shims 3 are shown as all being of thesame shape/dimensions, it is within the scope of the present inventionto vary the size, shape and dimensions of the respective cut/shimcombination. Although it is preferred that shims 3 are manually ormechanically inserted into the respective cut 2, and pushed inside cut2, it is possible to provide shims 3 having a length greater than thedepth of the respective cut 2, and after insertion, remove any portionoutside cut 2, and optionally a small section to provide an opening fora cutting blade, as described below. It is additionally possible to useshims 3 which have a smaller width, in combination with an adhesive orsealant to maintain shim 3 in position. If, however, cut 2 issufficiently small, it is possible to eliminate the need for shim 3.

The material for shims 3 is preferably an olefin, polyester, or othermoldable and/or extrudable thermoplastic or thermosetting material suchas vinyl; solid or engineered wood or other cellulosic material, ormetal. It is additionally within the scope of the invention to providethe material for shims 3 in a flowable form, which sets, hardens ordries into a solid form. The material may also be expandable, such as byfoaming or by heating or chemical reaction, such that after expansion,the material substantially fills the respective cut 2. In preferredembodiments, the material for shims 3 is substantially incompressible,once set/hardened/dried.

In an alternate embodiment, the interlayer (as previously described) ispositioned in alignment with the cuts 2, such that removal of thevarious sections is easily accomplished once the covering 4A is cut,sliced, scored, etc. In one embodiment, the interlayer allows for thesections to be peeled away. In another embodiment, the interlayer isprovided with a notch therein, to facilitate easy separation from theremainder of the generic element 5; however, it is considered within thescope of the invention to provide an interlayer without any notch, whichnotch can be formed during the slicing, cutting, scoring, etc. of thecovering 4A.

FIG. 4 shows structure 1 having a covering 4A thereon. In a preferredembodiment, covering 4A is a laminate formed from a thermosetting resin,having a décor sheet, optionally an overlay layer (with or without loosecellulosic fibers atop or therein) or sheet and hard particles inproximity thereto (e.g., in, on, above, or below, with or without aseparate structure therebetween) in order to impart an abrasionresistance thereto, which is affixed to structure 1 in a high-pressurelaminate process step. Such laminate may be affixed to structure 1 asdescribed by U.S. Pat. No. 6,805,951, herein incorporated by referencein its entirety. Covering 4A can also be other finishing materials suchas thermoplastic containing laminates, wood veneers, thermosettingpolymers, such as vinyl or polyesters, thermoplastic polymers such asolefins, foils (such as thermosetting, thermoplastic, paper or metalfoils), impregnated with or without hard particles, polyester, metals(such as sheets or single or strips), or combinations thereof. Forexample, covering 4A can include multiple elements, as described herein.It is additionally considered within the scope of the invention to affixcovering 4A during a direct lamination step, as is known in the art.

Once covering 4A is applied, structure 1 can be shaped to form thegeneric molding 5 as to be sold. As shown in FIG. 5, generic molding 5may have one more notches 5A disposed in under face 1E. Such notches mayadditionally include elements or structures as described by U.S.application Ser. No. 11/343,199, herein incorporated by reference in itsentirety. Such shaping may be performed by manual or automated cutting,such as by severing, broaching, machining, routing, sawing, chipping,planning, sanding, or by any other method for removing material from thestructure of structure 1. Of course, the method used to shape structure1 is usually selected depending upon the material used for structure 1and the desired shape for generic element 5. For example, if structure 1were extruded or molded, it is possible to form structure 1 with thenotches 5A therein, such that a separate shaping step is not necessary.

Typically, generic element 5 can be manipulated by a further shapingstep to form more than one flooring molding. Thus, the configuration ofgeneric element 5 depends upon the desired traditional flooring moldingspotentially formed by manipulating generic element 5. Accordingly, FIG.5 shows a typical generic element 5 in accordance with the invention.

As shown in FIG. 5, generic element 5 has a first removable section 5Cand a second removable section 5D connected to a central section 5E atconnections 5B. Connections 5B are typically ledges or other elements,which hold removable sections 5C and 5D to central section 5E. AlthoughFIG. 5 shows connections 5B as being merely extensions of the materialof core 1A, it is additionally within the scope of the invention to formconnections 5B as frangible joints, friction joints, tongue-and-groovejoints, compression joints, glue (or other adhesive), or any combinationthereof, in order to maintain such connections 5B made without anyphysical connections because the cut goes all the way, relying, at leastin part, on covering 4A to maintain structural integrity. The variousseparable sections of the invention are preferably break-away sections,i.e., can be separated from other sections in a single unitary piece bybreaking a connection between the break-away section and at least oneother section. In contrast, when a milled-away section is removed fromanother section, such milling does not form a unitary piece, but rathersmaller particles, such as dust.

Due to the construction of generic element 5, including covering 4A andconnections 5B, various flooring profiles or moldings can be formed.Removing removable sections 5C and 5D from generic element 5 can producea T-molding 6, while removing only section 5C from generic element 5 canproduce a carpet reducer 7, and removal of only section 5D from genericelement 5 can produce a hard surface reducer 8. If core 1A is providedwith a cut 2B in upper surface 1B, it is further possible to divideT-molding 6 to form two end moldings 10.

Similarly, a generic molding can be manufactured having only tworemovable sections, such that in its original configuration, the genericmolding is a T-molding 400 (FIG. 24), and when separated along breakaway401, two end moldings 402 are produced (FIG. 26). This T-molding 400 canbe used in combination with a reversible element 402 (FIG. 25) to form aHSR or CR (depending upon the orientation of reversible element 402), asdescribed by U.S. application Ser. No. 11/066,099 and U.S. applicationSer. No. 11/343,199, each of which is herein incorporated by referencein its entirety. The T-molding 400 and reversible element 402 can beused with a different track 404 to hold the resulting assembly in place(FIGS. 27-32). When the end molding 402 is to be used with a securingelement, preferably an alternate track 405 is used (FIG. 31). The track405 can be formed by cutting or breaking track 404 to match thelatitudinal length of the end molding 402.

Another generic molding which can be used without manipulation isT-molding 501 (FIG. 38). This T-molding 501 has a number of removablesections 502, 503, and 504 (A and B), which can produce differentshapes. For example, removal of sections 503 and 504B can produce a CR501A (FIG. 39). Removal of section 504B only could produce a firstmodified T-molding 501B (FIG. 40), which can be used for shallow tile,vinyl or low carpet (e.g., Berber). Removal of sections 502, 503, 504Aand 504B can produce a second modified T-molding 501C (FIG. 41) forhigher floorings, such as tile and hardwoods and deeper carpets.

In other embodiments, it is possible to create other flooring profilesor transitions from generic molding 5. For example, removable section 5Cor 5D can be shaped to form a traditional quarter-round molding whenremoved from section 5E. Additionally, generic element 5 may be shapedto form a traditional stair nose molding when one or both of removablesections 5C and 5D are separated. Thus, it is considered within thescope of the invention to shape generic molding 5 such that whenseparated, removable section 5C can be used as a quarter-round molding,while the remaining structure, i.e., section 5D joined to section 5E,can be used as a stair nose molding, as discussed below.

In one embodiment, covering 4A must be cut or severed in order toseparate the removable sections. Such a process typically requires theuse of a specialized tool, which divides covering 4A, e.g., with a bladeor other cutting tool, along the respective cut 2. Once covering 4A hasbeen subdivided, it becomes possible to separate any necessary removablesections. Typically, a great deal of force is required to breakconnection 5B, such that if the generic molding 5 were used with theremovable section in place, the generic molding 5 would maintain itsstructural integrity, although in other embodiments, little or no forceis required. The cutting tool or a second tool can be used to providethat force, for example, a standard flat-head screwdriver or othernarrow width tool can be inserted into cut 2, either through the slot insevered covering 4A or from a longitudinal end of generic molding 5, andthe removable section pried from the remainder of generic molding 5.Thereafter, the remaining part of generic molding 5 can be sanded toremove any burrs or other rough surfaces created during the prying. Inone embodiment, the cutting, prying and sanding can all be performed bythe same tool. Thus, it is possible to package one generic molding 5along with the three-function tool.

A cutting blade 1000 can also be used as part of a tool to separate theelements of the generic molding 5, with different embodiments shown inFIGS. 45A-E. In one embodiment, the cutting blade is substantiallycircular, and can be made of any conventional cutting material, e.g.,ferrous or non-ferrous metals (such as stainless-steel) or ceramics.While the blade 1000 typically has a thickness of between 0.2 mm and 0.3mm, the thickness of the blade 1000 should be selected depending uponthe desired thickness of the resulting cut 2. In a preferred embodiment,the blade 1000 rotates, as it can be circular or non-circular.Additionally, the blade 1000 can be stationary or reciprocate as itcuts. For example, the blade 1000 can have a substantially rounded shape(e.g., elliptical), such that as it rotates, the cutting surfacereciprocates against the surface to be cut.

The cutting blade can have a smooth bevel FIG. 45A, where one bevel fromeach side of the blade meets equidistant to the center thickness of theblade, such that the two bevels are of equal length. However, one bevelmay be longer than the other. The cutting blade may also have a singlenon-beveled cutting edge (FIG. 45B), where cutting edges are on eachside, running from one side through the entire thickness of the blade tothe opposite side, resembling a wedge shape around the perimeter of thecircular blade.

A non-beveled (e.g., square-edge) blade FIG. 45C can be used, where thecutting edges are on each side of the perimeter of the circular bladecreated by a vertical or near vertical or perpendicular surface ratherthan the one edge created by a beveled surface around a circular blade.An advantage of this “vertical edge” blade, depending upon the materialcut, is sanding of the cut edge of the material may not be necessary,saving an additional operation that maybe required when using a bevelededge blade.

In one embodiment a rounded edge blade FIG. 45D is used, without anycutting edge. This type of blade presses through the covering materialinto the void beneath the material creating, depending upon thematerial, a rolled edge that in many cases will not require sanding orsmoothing. The perimeter of the blade typically has a semicircularsurface running smoothly from one side of the blade side surface to itsopposite side.

A reverse double or chevron-shaped blade (FIG. 45E) can also be used.This blade has the advantage of cutting along both angled surfacessimultaneously.

Such cutters or blades can be stationary or moveable, e.g., byreciprocating, but are preferably rotating and can be used to cutsurface materials that are placed over a shaped, extruded or molded corematerial that is scored, has cuts or extruded or molded grooves.Typically the core is made of wood based material, e.g., fiberboard,such as HDF, MDF, particle board or solid wood, composites, plastics ormetals that can be covered by a variety of surface materials such aswood veneer, foils, laminate, paper, metal, plastic, cork, leather,linoleum, vinyl, rubber, bamboo, ceramic or glass tiles, textiles andthe tool may be designed to score the surface of hard materials such asceramic, making it possible to break the ceramic after the scoring.Although it is preferred that breaking or separating connection 5Brequire the use of a tool, it is within the scope of the invention tohave a weaker attachment. For example, connection 5B may be broken byhuman hand and arm pressure alone, i.e., without the use of any type oftool.

A specialized cutting tool 1100 is preferably used to cut the structure1 into the separate parts. The tool 1100 has a body 1101, defining aworkspace 1102, into which the structure 1 is passed. In a preferredembodiment, the tool 1100 has a length no greater than the width of thestructure 1, to allow for simple packaging of a tool 1100 with astructure 1. The tool 1100 typically includes a horizontal cutter 1103and a vertical cutter 1104, in which separate cutting blades 1000 arelocated. Preferably, each of the cutting blades 1000 in the tool 1100are of the same structure, but it is within the scope of the inventionto have different blades 1000. Each of the blades 1000 are connected toan axis 1107, which axis is mounted in a horizontal cutter housing 1108or a vertical cutter housing 1109, respectively. The vertical cutter1104 preferably penetrates the body 1101 through vertical cutteraperture 1110.

During use of the tool 1100, the structure 1 is relatively moveablethrough the workspace 1102 to come in contact with either the horizontalcutter 1104 and/or vertical cutter 1104, depending upon the desiredshape of the structure 1 after cutting. Specifically, the structure 1can be moved with respect to the tool 1100, the tool 1100 may be movedwith respect to the structure 1, or both the 1100 and the structure maybe moved with respect to each other. For example, if the structure hasan initial shape as shown in FIG. 5, and only section 5D is desired tobe removed, the structure can be inserted into the workspace with cut 2Cpositioned toward the horizontal cutter 1103. As the structure 1 passesthe blade 1100, the edge of the blade 1100 will penetrate sever thecovering 4A, thereby exposing the cut 2C. Depending upon the particularconfiguration of the structure 1, section 5D can then be removed by, forexample, simply allowing it to fall away, separating a glue, pryingand/or snapping section 5D from the remainder of the structure 1.Additionally, an additional tool, such as the operative end of aflat-head screwdriver can be inserted into the cut 2C and twisted toassist in the separation. Finally, the structure 1, having been cut, canbe sanded if needed to remove any jagged or rough ends formed by theremoval step. In a preferred embodiment, once the covering is severed,the individual pieces can be separated by hand and arm pressure alone orwith the use of a tool.

In order to prevent the vertical cutter 1104 from severing cut 2B whensuch severing is not desired, the blade 1000 inside the vertical cutter1104 is typically moved away. This can be accomplished by simply pullingup on the vertical cutter 1104 to move the blade 1000 therein upwards tomove the blade to an inoperative, yet preferably retained in the tool1100, position, or the vertical cutter housing 1109 be physicallydisconnected from the tool 1104, allowing removal of the blade 1000therein, depending upon the particular configuration of the tool 1100.

If, after section 5D is removed, the user wants to form a T-molding byremoving section 5C, the structure 1 can be relatively moved through theworkspace 1102 a second time, whereby the blade 1000 in the horizontalcutter 1103 severs the covering 4A over cut 2A. Thereafter, section 5Cis removed.

Finally, if the user desires to form an end molding, e.g., as shown inFIG. 9, the structure 1 can be passed through the tool 1100, with theblade 1000 inside the vertical cutter 1104 in the operative or engagedposition. Accordingly, the vertical cutter 1104 will sever the coveringover cut 2B. As the tool 1100 can be operated with one or both of thevertical cutter 1104 and the horizontal cutter 1103 in an operativeposition, it is possible to use both cutters simultaneously or in anysequence to achieve the desired configuration of the structure 1 (e.g.,the cut 2B can be formed before cut 2A or 2C). In a less preferredembodiment, the tool 1100 is provided with a removable and/or detachablesecond horizontal vertical cutter 1103′ (not shown) positioned oppositethe first horizontal cutter 1103 to permit all three severing steps tobe performed at the same time or in any desired sequence without havingto install the cutters.

In a much preferred embodiment, when making the end moldings using thevertical cut in the center leg, all three cuts are made before anypieces are separated from the one piece structure. Thus, the fullstructure is intact to help the tool 1000 to operate correctly.

Once all three cuts are made the “T” can be separated in half and thenthe HSR and CT parts can be separated from the “½ T” (End Molding Part)and/or the HSR and CT parts can be removed along the horizontal cuts andthen the “T-Molding can be divided in half along the vertical cut intotwo end moldings. Ideally we can break these parts off with handpressure alone.

It is also within the scope of the invention to provide each of thecutters 1103, 1104, 1103′ with multiple blades 1000. For example, thecutters can have 2, 3, 4, or 5 individual blades, each of which can beof any of the shapes and types described herein. One or more blades canindependently rotate or be stationary, and/or one or more blades mayindependently reciprocate. There may also be a single blade 1000 whichis interchangeable between the different cutters. In a preferredembodiment, the vertical cutter 1104 and horizontal cutter 1103 aredesigned such that the entire cutter can be removed from the horizontalposition and placed in the vertical position, or vice versa. In such anembodiment, only one cutter need be provided to perform all of thecutting functions.

A second cutting tool 1200 is schematically shown in FIG. 48, andoperates in a substantially similar manner to the first cutting tool1100. The cutting tool 1200 includes a body 1201 and a lower section1202 defining a workspace 1203 therein, with the blade(s) 1000 beingmounted similarly to as described in connection with the first cuttingtool 1100. Typically, the lower section 1202 is fixedly joined to thebody 1201, either by being integrally formed with or affixed thereto by,e.g., screws, glue, or straps. Again, in a preferred embodiment, thetool 1200 has a length no greater than the width of the structure 1, toallow for simple packaging of a tool 1200 with a structure 1. The tool1200 typically includes a cutter 1204 which can be placed in itshorizontal position, or in the alternative, in its vertical position.Depending upon the particular cutting of the structure 1 to be made, thecutter 1204 can be shifted from the first position to the sectionposition. This is typically accomplished by pulling the cutter 1204distally outward to disengage the blade 1000 disposed therein from itslocation where it can engage the structure 1, and sliding the cutter1204 along the body 1201 until the cutter reaches the second operativeposition. Preferably, when in the disengaged position, the blade 1000 isretained inside the tool 1200. Thereafter, the cutter 1204 can be pushedto move the blade 1000 such that it can engage the structure 1 in thesecond operative position.

In another embodiment, the cutter 1200 is provided with a second cutter1204′, such that a vertical cut and a horizontal cut can be madesimultaneously. Accordingly, in order to prevent unwanted severing ofthe structure 1, either or both of the cutters 1204, 1204′ can beremoved entirely or simply disengaged from the operative location.

Because shim 3 is inserted into cut 2, separation of a removable sectionfrom generic molding 5 often will cause shim 3 to fall out. However,instead of simply discarding shim 3 as trash, shim 3 may be used as ashim to be utilized when installing any resulting molding, above orbelow any means for attaching the resulting molding, such as a track orclamp.

As covering 4A is preferably applied to core 1A in one piece, as isdescribed by U.S. Pat. Nos. 6,517,935 and 6,898,911 (each of which isherein incorporated by reference in its entirety), covering 4A shouldnot have any dividing lines or other demarcations marring the decorativesurface.

Often, covering 4A is provided with a patterned paper sheet therein,wherein the pattern resembles a natural or synthetic object, such aswood, ceramic, stone (including marble and granite), or fantasy patterns(i.e., those not found in nature), including a monochromatic or randomfield. The specific generic molding 5 can be selected to enhance theappearance of the surfaces which will be adjacent to the generic molding5 (or parts thereof) when installed. Such enhancement can beaccomplished by matching exactly the visual pattern of generic molding 5to that of the adjacent surface, or by contrasting the patterns, forexample, such that when installed, a visual pattern extends from aflooring element onto and possible completely across the molding.

Moreover, it is possible to provide covering 4A with a textured uppersurface which enhances the pattern of the underlying paper sheet. Suchtexturing can be created to be “in register” with, offset from, or tocontrast with the image of the paper sheet. Such texturing may becreated by physical pressing, e.g., embossing (as taught by U.S.application Ser. No. 10/440,317 (filed May 19, 2003), U.S. Pat. No.7,003,364, WO9731775 and WO9731776, each of which is herein incorporatedby reference in its entirety) or chemically created (as taught by U.S.Pat. No. 6,991,830, herein incorporated by reference in its entirety).The texture of the covering 4A can be selected by the installer toenhance (e.g., match or contrast with) any texture of adjacent surfaces.

It is additionally possible to provide removable sections 5C and 5D withopposite decorative surfaces (as disclosed by U.S. application Ser. No.10/748,852, Nos. 11/066,099, and 11/343,199, each of which is hereinincorporated by reference in its entirety), such that after beingremoved from generic molding 5, removable sections 5C and/or 5D can bere-attached in a reverse configuration to section 5E by, for example,tongue-and-groove joints, friction joints, or adhesive. By providinggeneric molding 5 with reversible structures, the number of functions ofthe single product can be greatly increased.

FIG. 10 shows a different embodiment for a CR/HSR 100. When installed asa carpet reducer (“CR”), the end of the carpet adjacent CR/HSR 100 canbe tucked or turn against a vertical face 119 of removable section 105.When used as a hard surface reducer (“HSR”), inclined surface 120provides an angular surface that graduates the height differencesbetween two flooring surfaces. A foot 109 is provided on CR/HSR 100 toallow for connection to track 110, as described below. Foot 109 ispreferably formed from the same material as the remainder of CSR/HSR100, but alternatively, may be formed from a different material througha different process and thereafter, joined to the remainder of CR/HSR100. Similarly, foot 109 can be joined to the remainder of CR/HSR 100by, for example, an additional connection 5B, such that, if desired,foot 109 can be removed. As with generic element 5 (FIG. 5), removablesection 105 is preferably attached by a connection 5B, formed by thecreation of a cut 2 (with or without a shim 3 placed therein), and canbe removed from CR/HSR 100 to form a T-molding, such as shown in FIGS. 6and 11. In a preferred embodiment, removable section 105 is providedwith a tab 108 that can fit and rotate with a corresponding groove 116in a securing element (described below).

In FIG. 11, removable section 105 has been removed to create a T/Endmolding 104. T/End molding 104 can be connected to a securing element110, which securing element 110 is preferably not affixed to asub-floor. Securing element 110 is, however, preferably affixed to oneor both adjacent flooring elements 103A, 103B. This can be accomplishedwith a fresh adhesive, pre-glue, magnetically, or by any conventionalmechanical device, such as a screw, nail, etc. Arms or extensions ofT/End molding 104, as well as T molding 6, can overlap finished flooringapproximately 0.25″-0.75″ (approximately 6.5-20 mm), preferablyapproximately 0.5″ (13 mm).

An underlayment 102 can be placed between flooring elements 103 andsubfloor 101. Underlayment 102 can be any conventionally knownunderlayment, such as those used as moisture barriers and/orsound/shock/electric charge dampening, and can be affixed to flooringelements 103, or simply laid down before flooring elements areinstalled. It is additionally considered within the scope of theinvention to utilize an underlayment which creates moisture channelsbelow flooring elements 103, such as PLATON STOP and/or PLATON FLOOR, byIsola as of Norway, such as described by U.S. patent application Ser.No. 11/522,535, herein incorporated by reference in its entirety.

As shown, T/End molding 104 overlaps the flooring elements 103A, 103B.This allows the T/End molding 104 to function, with sufficient space forexpansion or contraction of flooring elements 103A and/or 103B withoutthe need to anchor securing element 110 to the subfloor. Additionally,if the flooring elements 103A, 103B are not secured to the securingelement 110, each of the flooring elements 103A could move independentlyof each other. It is also considered within the scope of the inventionto affix securing element 110 to one of the flooring elements 103A,which would cause T/End molding 104 to move with flooring element 103A,while the other flooring element 103B would not be so constrained.

A preferred securing element, or track 110 to be used with the moldingsof the invention is shown in FIG. 12. Track 110 is preferably made of aplastic, metal or composite material, and can be used to secure any ofthe parts described herein to flooring elements 103A, 103B and/or asubfloor. Vertical portions 112 are shown as upstanding from base 111.Although shown as being perpendicular to base 111, vertical portions 112can be at any angle therefrom. For example, while a first verticalportion 112A can be perpendicular to base 111, a second vertical portioncan be disposed at any angle. In one preferred embodiment, verticalportions 112 are upstanding from base 111, but angle towards each other.As a result, vertical portions 112 are biased inwards, and the biasingassists in holding the molding in place.

First wing 113 is a portion of base 111 which is designed to be placedbelow a flooring element 103 (as shown in FIG. 11). A distal portion113A of wing 113 can be folded back 180° to form a shim, in order toraise track 110 or other parts to accommodate thicker flooring elements103.

Disposed adjacent to, but preferably not in contact with, a verticalportion 112 is a second vertical portion 114. This second verticalportion helps to support, for example, removable section 105, bypreventing back and forth movement. When removable section 105 isstepped on, rolled over, or otherwise subjected to forces tending topush it inwards, second vertical portion 114 acts to maintain removablesection 105 in the correct location.

Track 110 can also have a second wing 115, which second wing 115 caninclude a pre-applied adhesive (e.g., an encapsulated glue as describedby U.S. Pat. No. 7,029,741 and application Ser. No. 10/270,163, each ofwhich is herein incorporated by reference in its entirety), adhesivetape, fresh adhesive or can have a mechanical or magnetic attachment (asdescribed by U.S. application Ser. No. 10/747,261, herein incorporatedby reference in its entirety) to affix track 110 to the underside offlooring elements 103 and/or the subfloor. Second wing 115 may also beprovided with a groove 116, sized and shaped to receive tab 108, whichhelps to hold removable section 105 in place and, simultaneously, allowsremovable section 105 to rotate in adjustment as the height of flooringelements 103 increases. It is considered within the scope of theinvention to swap the relative locations of the tab 108 and grove 116.

It is additionally possible to utilize a track having a singleupstanding section, positioned between lower lateral ends (such as shownin FIG. 1A of both U.S. Published Patent Appl. No. 2003/0084634 and No.2003/0154678 each of which is herein incorporated by reference in itsentirety). Such a track can be inserted into a groove positioned in anunderside of generic structure 5. In one embodiment, the foot, or middlelower depending portion of generic structure 5 can be reduced in size oreliminated, as the interaction between this track and groove can besufficient to hold the structure in its installed condition.Additionally, an uppermost end of the track can be provided with barbs,spikes, projections, joint elements (such as tongue/groove) or otherelements which can enable the track to lock or more securely hold thestructure in its installed condition.

In FIGS. 13 and 14, T/End molding 104 is shown, in an installedcondition, as a carpet/hard surface reducer (with removable section 105)and an end molding (without removable section 105), respectively. As canbe seen, foot 109 of T/End molding 104 is secured in track 110 byvertical sections 112. Track 110 is secured to a subfloor 101 with anadhesive, magnetic forces or mechanical attachments. In FIG. 14, T/Endmolding 104 is installed adjacent a wall 118. A sealant or adhesive 117may be placed in any gaps between T/End molding 104 and anotherstructure, such as a wall 118. As shown in FIG. 14, T/End molding 104can be used without any securing element, as the presence of adhesive117, may be sufficient to maintain T/End molding 104 in place. Suchsealant or adhesive can be a fresh glue or a pre-applied glue (e.g., a“preglue” applied at the factory). In a preferred embodiment, adhesive117 is a foaming adhesive, e.g., a silicone sealant or alternate foamingadhesive, such that after adhesive 117 and T/End molding 104 areinstalled, adhesive 117 foams or expands to fills voids between wall 118and T/End molding 104.

FIGS. 15-22 depict an additional molding assembly of the invention. Thisextrudable assembly 202 is preferably formed from an extrudablepolymeric, composite or metal material, but may also include or besubstituted by milled composite materials, wood, fiberboard, or anyother material discussed herein suitable for core 1A.

Typically, assembly has a decorative outer surface 201, which surface201 is preferably selected from the same materials for the outer facesof structure 1.

As shown, assembly 200 can be constructed with a combination HSR/CR 202and a T-molding 204 (which need not be of the same material), joined atbreakaways 204. Breakaways 204 can be narrowed or scored or othersections of assembly 202, allowing for separation of the parts ofassembly 200. Breakaways 204 can also be joints between two separateelements, formed by, for example, friction joints, tongue-and-groovejoints, compression joints, glue, or any combination thereof.

Assembly 200 can be fixed to a subfloor using any material describedherein, such as adhesive (e.g., pre-applied or fresh glue), tape ormagnetic strip (optionally with tape or adhesive). Installing assembly200 in a first configuration produces a HSR, while inverting assembly200 produces a CR (FIG. 18).

By providing one set of legs 208 on assembly 200, assembly 200 can beused in a variety of configurations. As can be seen in FIG. 15, applyingforce to push or pull the sections of assembly 200, different shapes, toaccommodate different flooring heights. Desired positions for legs 208can be selected and locked in place by utilizing a glue, sealant, epoxy,or other chemical element, or in the alternative (or in combinationwith), barbs or teeth 212.

By splitting or breaking assembly 200 at breakaways 206, differentmoldings can be realized. Another T-molding 220 is created by separatingassembly 200 at each of breakaways 206B and 206C. This T-molding 220 ispreferably joined to one flooring element with an adhesive 222, whichcan take the form of any glue or adhesive described herein, butpreferably is a peel-and-stick adhesive, and is positioned to join toboth an upper surface and a lower surface of the flooring element. Sucha construction, similar to other embodiments, allows T-molding 220 to“float” with the joined flooring element, independent of other flooringelements. In another embodiment, T-molding 220 can be affixed to thesubfloor with any glue, adhesive or magnetic means (discussed herein),alone or in combination with affixing to the flooring element.

If assembly 200 is split or separated at breakaways 206A and 206C, anend molding 230 can be produced (FIG. 17). The end molding 230 can beaffixed to the upper surface of an adjacent flooring element, or if usedin combination with a track 232, both the track 232 can be joined toeither the subfloor or the underside of the adjacent flooring element,alone, or in combination with the end molding 230 being affixed to theflooring element. If the end molding 230 is used without the track 232,a lower end of end molding 230 can also be affixed to the subfloor.

An alternate embodiment of the assembly 200 shown in FIG. 15 is anadditional assembly 250 (FIGS. 19 and 20), which can also function as aHSR or CR, depending upon its installed orientation. This assembly 250has a supporting strut 252 that is adjustable and can move whenadjustable legs 253 are raised/lowered for different finished flooringthicknesses. The adjustable strut 252 provides additional strength tothe structure of the assembly 250. In order to prevent strut from movingonce installed, it is considered within the scope of the invention toprovide a locking mechanism, such as barbs, glues/adhesives, or othermeans for maintaining the strut 252 in its desired configuration. Justas the assembly 200 can be separated at various breakaways, the assembly250 can be broken at breakaways 254A-C for form various products. AT-molding 256, and its optional associated track 256 (FIG. 21), can beformed by separating assembly 250 at breakaways 254B and C. Two endmoldings 257 (FIG. 22) can be produced by separating assembly 250 atbreakaways 254A, B and C.

Another embodiment of the generic molding of the invention is shown asgeneric molding 300 (FIG. 23). The generic molding 300 is a breakawayversion with multiple horizontal sections for forming a versatilemolding capable of being used for a large range of finished flooringthicknesses. This version can be an extrusion or other milled or shapedmaterial such as HDF, MDF, composites, metal, wood or plastic. A core301 of the generic molding 300 can also be manufactured from anystructural material discussed herein in connection with otherembodiments of the invention. Similarly, a finished surface material 302covers at least a portion of the core 301 and preferably provides thegeneric molding 300 with a decorative outer surface, and may be any typeof decorative surface discussed elsewhere herein. When in a desiredconfiguration, the generic molding 300 is preferably installed with atrack 303, which track can include one or more gripping flanges 303Awhich can interact with one or more gripping grooves 303B (not shown) tohelp to maintain the generic molding in place. In a preferredembodiment, the generic molding 300 is provided with rounded shoulders304, formed as part of the core 301 or as an additional structure, whichbears against legs of the track 303 to add support to each of thesections holding the generic molding 300 in place.

In order to use the generic molding 300 in various configurations, thegeneric molding 300 is typically provided with breakaways 305A-D, toindependently reduce the height of the core 301 of the generic molding300 to form a T molding, end molding, CR or HSR as discussed herein, fora number of heights. Although shown with a particular number ofremovable sections on each side of the generic molding 300, it isconsidered within the scope of the invention to increase or decrease thenumber, size and shape of the sections, such that, for example, thenumber of sections on one side is unequal to the number of sections onthe other side.

The invention additionally includes a stair nose assembly 600 (FIGS. 33Aand 34). In a first embodiment, the stair nose assembly 600 can beformed by joining a T molding (such as T-molding 6, 220, 255, 400, orT/End molding 104) with a structure (such as end moldings 10 and 230).The joint formed at the junction between the T-molding and theadditional structure can be maintained by any means discussed herein,such as adhesive/glue or other chemical or mechanical element. Byforming the elements of stair nose assembly 600 with matching décor, auniform appearance can be achieved.

Preferably, however, stair nose assembly 600 is a unitary structure,sold as a single unit, consisting of a first section 601, and a secondsection 602, manufactured as a single structure. Typically, the stairnose assembly 600 includes a core 603 and a covering 604, which areselected from the cores and covering materials discussed elsewhereherein. In one embodiment, the stair nose assembly 600 is provided withcuts 605A-C which permit the stair nose assembly 600 to be used forother purposes after being separated at cuts 605A-C. For example,dividing at cut 605A produces an end molding 10, while dividing at cut605B produces both an end molding 10 and a T-molding 6. Dividing at cut605A and 605C can produce an element which can be used as a quarterround or shoe molding 606 (FIG. 33B).

An alternate stair nose assembly 610 can be formed by forming a carpetreducer 611, substantially similar to the carpet reducer 7, having agroove 612 in a lower surface thereof. By joining a stair noseattachment 613, by inserting a tongue 614 thereof into the groove 612,the stair nose assembly 610 can be formed. Similarly, stair noseassembly can be manufactured as a single piece by joining the carpetreducer 611 to stair nose attachment prior to adding the decorativesurface thereof, or by forming the stair nose assembly 610 as a unitarystructure, allowing for removal of stair nose attachment 613 atinstallation, at, for example, cut 615. When removed, stair noseattachment 613 can be used as a shoe molding or quarter round molding.

Each of the stair nose assemblies 600 and 610 can be affixed directly tothe subfloor with a mechanical, chemical or other attachment means asdiscussed herein. Alternatively, a track may be used to secure the stairnose assemblies 600 and 610.

One preferred method for forming a generic molding element 650 is shownin FIGS. 35-37. By this method, individual pieces are separatelymanufactured and held together in place by the covering material. In afirst step, two end moldings 650A and 650B, a carpet reducer part 605Cand a hard surface reducer part 605D are milled or otherwise shaped froma core material (as disclosed herein) and held together (FIG. 36). Thiscan be accomplished by, for example, using a clamp, other mechanicalelements or a glue (sufficient to hold the pieces together until thecovering is applied). Once the pieces are held together cuts 611-613 canbe made, and thereafter, a covering 654 (as discussed herein) isapplied. Through this method, the covering 654 (and optionally the glue)holds the generic molding element 650 together.

The molding of the invention can be produced by forming the genericstructure, and providing cuts therein, before affixing the coveringthereto. In one embodiment, the separable parts are completely removedfrom each other and can be held in place by a clamp or a mold, until thecovering is affixed thereto.

In another embodiment, the covering can be affixed to the genericstructure prior to the separable elements being formed. Typically, thecuts are formed in the underside of the structure, as the upper surfaceof the generic structure has the covering thereon.

In one embodiment, the invention uses a paper (with or without hardparticles—e.g., having a Moh's hardness of at least about 4 or 6,preferably at least about 7, therein, which can be alpha-aluminum(alumina), silicon carbide, diamond, cerium oxide, zirconium oxide,and/or glass beads), and once printed, is impregnated with athermosetting resin. The impregnated paper is then further combined withother layers and elements to form a laminate which can be bonded to acore material.

Suitable core materials include one or more of wood, fiberboard, such ashigh density fiberboard (HDF) or medium density fiberboard (MDF),polymer (thermosetting and thermoplastic), flaxboard, stone (e.g.,ceramic, marble, slate), cardboard, concrete, gypsum, high density fiberreinforced plaster, veneers such as plywood, oriented strand board,cores made from particles (including discrete pieces of polymer or wood,which can be in the form of chips, curls, flakes, sawdust, shavings,slivers, stands, wavers, wood flour, wood wool and/or fibers), and otherstructural materials, such as metals (e.g., brass, aluminum, steel,copper, composites, composites or alloys). In some embodiments, the corematerial can be foamed (either open cell or closed cell), such aspolyurethane. In still further embodiments, the core is made as acomposite from multiple materials (such as those listed above), eitheras a heterogeneous mass, multiple layers or defined sections, e.g.,upper and lower veneers covering a core of particles. Any of the abovematerials may also be provided with antistatic or antibacterialproperties, e.g., by the inclusion of silver flakes, powders orparticles, carbon black, ceramics, or other metals or alloys. Preferredplastics include extrudable and/or moldable thermosetting andthermoplastic resins, the latter including high density olefins andpolyvinylchloride.

This laminate may also be covered with other types of coverings, such asfoils (such as metal, paper or thermoplastic foils), paints or a varietyof other decorative elements, including, but not limited to wood veneer,ceramic, metal, vinyl or other decorative materials.

In another embodiment, the décor is provided on the core materialitself, i.e., without the paper layer, e.g., as described by, e.g., U.S.Pat. No. 6,465,046 (herein incorporated by reference in its entirety).In one embodiment, the core is optionally provided with a primer and/ora base color, on which the decorative pattern or display is printed orotherwise generated. While the term “pattern” is used herein, it is tobe understood that “pattern” need not be or include any repeating units,thus “pattern” is simply a visual and/or textual display. Once the décoris complete, the printed décor can be covered with a wear layer, therebygiving the décor abrasion and/or scratch resistance. The wear layer canbe provided in the form of a sheet of alpha-cellulose which is bonded tothe core, or it can be applied in a liquid form, and is typicallyprovided with hard particles as described herein. The wear layer caninclude melamine-formaldehyde, urea-formaldehyde, maleamid, lacquers,acrylic resins, and/or urethanes.

Often, the result of the printing process of the invention resembles anatural or synthetic object, such as wood or wood tiles or boards,ceramic (e.g., tiles), stone (including marble and granite, such astiles), or fantasy patterns (i.e., those not found in nature), includinga monochromatic or random field.

Moreover, the invention can have a texture which enhances the pattern ofan underlying printed image. Such texturing can be created to be “inregister” with, offset from, or to contrast with the image of the papersheet. Such texturing may be created by physical pressing, e.g.,embossing (as taught by U.S. application Ser. No. 10/440,317 (filed May19, 2003), U.S. Pat. No. 7,003,364, and WO9731775 and WO9731776) orchemically created (as taught by U.S. Pat. No. 6,991,830). The texturecan be selected by the installer to enhance (e.g., match or contrastwith) any texture of adjacent or included surfaces. The texture may alsobe provided on the decor such that features of the texture extend from aflooring element onto and possible completely across the adjacentflooring elements, which texture may, or may not coincide with theunderlying décor. Each of the documents discussed in this paragraph areincorporated herein in its entirety.

The invention is typically used in the construction of a surface, suchas a top for a counter or table, floor, ceiling, or wall. Such surfacesare often found in residential structures (e.g., single and multi-familyhouses, condominiums, townhomes, co-operatives, apartments, and lobbiesof such buildings), commercial structures (e.g., retail stores, stripmalls, shopping malls, office buildings, hotels, restaurants,supermarkets, banks, churches, airports and other transit stations),public structures (e.g., stadiums and arenas, schools, museums,theaters, post offices, hospitals, courthouses and other governmentbuildings), as well as industrial structures (e.g., manufacturingplants, mills, and warehouses) and surfaces of vehicles (e.g., ships.trains, aircraft, public and private busses, cars and other motorvehicles).

It should be apparent that embodiments other than those specificallydescribed above may come within the spirit and scope of the presentinvention. Hence, the present invention is not limited by the abovedescription.

1. A method for forming an integral multi-purpose structure for formingflooring transitions comprising: providing a unitary core having anouter surface; imparting to the outer surface of the core at least onecuts thereby defining a plurality of break-away sections in the core,wherein the cuts are sized, shaped and positioned such that removal of abreak-away section of the core transforms the structure into a flooringtransition; and covering at least a portion of outer surface of the corehaving the at least one cut therein with a decorative material.
 2. Themethod of claim 1, wherein the providing comprises placing the cuts suchthat removal of a break-away section transform the core into a flooringtransition selected from the group consisting of a hard surface reducer,carpet reducer, T-molding, end molding, quarter-round, shoe molding,wall base and stair nose.
 3. The method of claim 1, wherein thedecorative material at least partially covers a cut in the core.
 4. Themethod of claim 1, wherein the imparting step comprises at least oneselected from the group consisting of milling and cutting.
 5. The methodof claim 4, wherein the cutting comprises using a blade or a laser. 6.The method of claim 1, comprising inserting a supporting material into acut before the covering step.
 7. The method of claim 1, wherein the corecomprises an interlayer positioned between the plurality of break-awaysections.
 8. The method of claim 1, wherein the core comprises amaterial selected from the group consisting of fiber board, particleboard, oriented strandboard, plywood, plastic, wood, engineered wood,metal, composites, gypsum, high-density reinforced plaster, and cork. 9.The method of claim 1, wherein the decorative material is printed atleast partially directly on the core to provide a decorative pattern.10. The method of claim 1, wherein the decorative material comprises apatterned paper sheet.
 11. The method of claim 1, wherein the decorativematerial comprises a wear layer comprising hard particles having a Moh'shardness of at least approximately
 6. 12. The method of claim 1, whereinthe decorative material comprises a wear layer comprising particlesselected from the group consisting of silica, alumina, diamond, siliconnitride, aluminum oxide, silicon carbide, cerium oxide and glass beads.13. A method of forming a flooring transition comprising: providing anintegral multi-purpose structure, the structure comprising: a unitarycore; cuts in the core, defining a plurality of break-away sections inthe core; and a decorative material covering at least a portion of thecore and the cuts; and severing the decorative material over the cuts inthe core; and removing at least one break-away section.
 14. The methodof claim 13, wherein the flooring transition is selected from the groupconsisting of hard surface reducer, carpet reducer, T-molding, endmolding, quarter-round, shoe molding, wall base and stair nose.
 15. Atool for severing a multi-purpose structure into a flooring transitioncomprising: a housing defining an interior space for receiving thestructure; a first blade position along a first side of the tool forsevering the structure along a first axis; a second blade position alonga surface of the tool different from the first side for severing thestructure along a second axis; and a blade located in the first bladeposition.
 16. The tool of claim 15, further comprising a second bladelocated in the second blade position.
 17. The tool of claim 17, furthercomprising a third blade located in a third blade position for cuttingthe structure along a third axis, wherein the third blade position issubstantially perpendicular to the first blade position andsubstantially parallel to the second blade position.
 18. The tool ofclaim 15, wherein the first blade position is substantiallyperpendicular to the second blade position.
 19. The tool of claim 15,further comprising means for moving the blade from the first bladeposition to the second blade position.
 20. The tool of claim 15, furthercomprising means for moving the blade from an operative position to aninoperative position,
 21. A kit comprising: the tool of claim 15 and anintegral multi-purpose structure, the structure comprising: a unitarycore; cuts in the core, defining a plurality of break-away sections inthe core; and a decorative material coving at least a portion of thecore and the cuts; wherein at least one of the blade positionscorresponds to the locations of a cut when the structure is movedthrough the interior space.
 22. The kit of claim 21, further comprisinga clamp or track.
 23. A flooring transition formed according to themethod of claim
 1. 24. A unitary structure for forming a flooringtransition comprising: a unitary core having an outer surface and cutspenetrating the outer surface, and a decorative material covering aportion of the outer surface and the cuts, wherein the cuts are sized,shaped and positioned to define a plurality of break-away sections inthe core, such that removal of a break-away section of the coretransforms the structure into a flooring transition.
 25. The structureof claim 24, wherein the core comprises a top face and two oppositelateral faces, and wherein each of lateral faces and the top facecomprise a cut.
 26. The structure of claim 25, wherein at least one ofthe lateral faces comprises a plurality of cuts.
 27. The structure ofclaim 24, wherein the core comprises a material selected from the groupconsisting of fiber board, plastic, wood, engineered wood, metal,composites, gypsum, high-density reinforced plaster, and cork
 28. Thestructure of claim 27, wherein the core comprises fiber board.
 29. Thestructure of claim 24, wherein the decorative material comprises oneselected from the group consisting of a foil, laminate, wood, woodveneer, ceramic, tiles, metal, vinyl, stone, paper, composite, andplastic.
 30. The structure of claim 24, wherein the decorative materialcomprises: a patterned paper sheet impregnated with a thermosettingresin; and a wear layer, the wear layer comprising hard particles havinga Moh's hardness of at least approximately
 6. 31. The structure of claim24, wherein the decorative material comprises a wear layer comprisingparticles selected from the group consisting of silica, alumina,diamond, silicon nitride, aluminum oxide, silicon carbide, cerium oxideand glass beads.
 32. The structure of claim 24, wherein: the corecomprises fiber board and the decorative material comprises: a patternedpaper sheet impregnated with a thermosetting resin; and a wear layer,the wear layer comprising hard particles selected from the groupconsisting of silica, alumina, diamond, silicon nitride, aluminum oxide,silicon carbide, cerium oxide and glass beads.